Hybrid thermoplastic composites for power tools and power tool components

Abstract

The embodiment of the invention relates to an electric tool. The power tool includes at least one hybrid composite component. The hybrid composite component includes a housing component and a composite component. The composite part is made of a first thermoplastic polymer matrix filled with long fibers wherein a majority of the long fibers have a length of at least 0.5 inches.

Description

[0001] Cross Reference to Related Patent Applications

[0002] This application claims the benefit of and priority to U.S. Application No. 63 / 490,961, filed March 17, 2023, the entire contents of which are incorporated herein by reference. BACKGROUND

[0004] The present disclosure relates to composite materials for reinforcing parts or components of power tools. SUMMARY

[0005] In a first aspect, embodiments of the present disclosure relate to a power tool. The power tool includes at least one hybrid composite component. The hybrid composite component includes a housing component and a composite component. The composite component is made of a first thermoplastic polymer matrix filled with long fibers, and a majority of the long fibers have a length of at least 0.5 inches.

[0006] A second aspect relates to the power tool of the first aspect, wherein the first thermoplastic polymer matrix of the composite component includes at least one of: polyamide (PA), polycarbonate (PC), polypropylene (PP), polyphthalamide (PPA), poly(butylene terephthalate) (PBT), poly(acrylonitrile: butadiene: styrene) (ABS), or polyketone (POK).

[0007] A third aspect relates to the power tool of the first aspect or the second aspect, wherein the long fibers include fibers selected from the group consisting of: glass fibers, carbon fibers, aramid fibers, basalt fibers, ultra-high molecular weight polyethylene fibers, and combinations thereof.

[0008] A fourth aspect relates to the power tool of any one of the first through third aspects, wherein the long fibers are randomly oriented.

[0009] A fifth aspect relates to the power tool of any one of the first through fourth aspects, wherein a majority of the long fibers are oriented within 15° of a common direction.

[0010] A sixth aspect relates to the power tool of any one of the first through fifth aspects, wherein the composite component includes a plurality of layers, and wherein each layer of the plurality of layers includes the first thermoplastic polymer matrix filled with long fibers.

[0011] A seventh aspect relates to the power tool of the sixth aspect, wherein the long fibers in each layer of the plurality of layers are oriented within 15° of a common direction, and wherein the common direction of a first layer of the plurality of layers is rotated about 45° or about 90° relative to the common direction of an adjacent second layer of the plurality of layers.

[0012] The eighth aspect is directed to the power tool of any of the first through seventh aspects, wherein the hybrid composite component has a thickness, and wherein the composite component comprises 80% of the thickness.

[0013] The ninth aspect is directed to the power tool of any of the first through eighth aspects, wherein the composite component is attached to the housing component without an adhesive.

[0014] The tenth aspect is directed to the power tool of any of the first through third aspects, wherein the housing component is formed of a same thermoplastic polymer as the first thermoplastic polymer matrix or a second thermoplastic polymer that is compatible with the first thermoplastic polymer matrix.

[0015] The eleventh aspect is directed to the power tool of the tenth aspect, wherein the housing component includes short fibers embedded in the same thermoplastic polymer or the second thermoplastic polymer, and wherein a majority of the short fibers have a length of less than 0.5 inches.

[0016] The twelfth aspect is directed to the power tool of any of the first through eleventh aspects, wherein the at least one hybrid composite component comprises an end cap of the impact driver.

[0017] The thirteenth aspect is directed to the power tool of any of the first through twelfth aspects, wherein the at least one hybrid composite component comprises a handle portion.

[0018] The fourteenth aspect is directed to the power tool of any of the first through thirteenth aspects, wherein the at least one hybrid composite component comprises a battery pack.

[0019] The fifteenth aspect is directed to the power tool of any of the first through eleventh aspects, wherein the power tool is a fastener driver comprising a gas spring mechanism, wherein the gas spring mechanism comprises a piston sleeve, and wherein the at least one hybrid composite component comprises the piston sleeve.

[0020] In a sixteenth aspect, embodiments of the present disclosure are directed to a power tool. The power tool includes a housing formed of a first thermoplastic polymer. The power tool also includes a composite component that reinforces a localized region of the housing. The composite component is formed of a matrix filled with long fibers, and the matrix includes a second thermoplastic polymer. The first thermoplastic polymer of the housing is melt bonded to the second thermoplastic polymer of the composite component.

[0021] The seventeenth aspect is directed to the power tool of the sixteenth aspect, wherein a majority of the long fibers have a length of at least 0.5 inches.

[0022] The eighteenth aspect is directed to the power tool of the sixteenth or seventeenth aspect, wherein the composite component includes 50% to 70% long fibers by weight.

[0023] The nineteenth aspect relates to the power tool of any one of the sixteenth aspect to the eighteenth aspect, wherein the composite part has a first thickness in a range of 0.1 mm to 3 mm.

[0024] The twentieth aspect relates to the power tool of the nineteenth aspect, the local area of the housing has a second thickness, wherein the first thickness and the second thickness together equal a total thickness, and wherein the first thickness is up to 80% of the total thickness.

[0025] In a twenty-first aspect, embodiments of the disclosure relate to an impact driver. The impact driver includes a housing having a head portion and a handle portion. An end effector is disposed on a first side of the first portion and is configured to hold a drill bit configured for drilling or for driving a fastener. An end cap is disposed on a second side of the first portion opposite the end effector. A trigger is disposed in the handle portion and is configured to actuate the end effector. The end cap is a hybrid composite part having a housing part and a composite part. The composite part includes long fibers disposed within a matrix of a first thermoplastic polymer.

[0026] A twenty-second aspect relates to the impact driver of the twenty-first aspect, wherein the housing part includes a second thermoplastic polymer, and wherein the second thermoplastic polymer of the housing part is melt-bonded to the first thermoplastic polymer of the composite part.

[0027] A twenty-third aspect relates to the impact driver of the twenty-first aspect or the twenty-second aspect, wherein the end cap is configured to deflect at most 3 mm when a force of 550 lbf is exerted on the housing perpendicular to the housing part.

[0028] In a twenty-fourth aspect, embodiments of the disclosure relate to a battery pack. The battery pack includes a first housing part and a second housing part configured to mate with the first housing part. The battery pack further includes a plurality of battery cells disposed within the first housing part and the second housing part when the first housing part mates with the second housing part. The second housing part includes a plurality of sidewalls and a plurality of corners, wherein each sidewall of the plurality of sidewalls is connected to an adjacent sidewall at a corner of the plurality of corners. At least one sidewall or corner is reinforced with a composite part, and the composite part includes a matrix of a thermoplastic polymer filled with long fibers.

[0029] A twenty-fifth aspect relates to the battery pack of the twenty-fourth aspect, wherein a majority of the long fibers have a length of at least 0.5 inches.

[0030] A twenty-sixth aspect relates to the battery pack of the twenty-fourth aspect or the twenty-fifth aspect, wherein the composite part includes 50% to 70% by weight of the long fibers.

[0031] The twenty-seventh aspect relates to the battery of any one of the twenty-fourth aspect through the twenty-sixth aspect, wherein the thermoplastic polymer matrix comprises a first thermoplastic polymer, wherein the second housing component comprises a second thermoplastic polymer, and wherein the first thermoplastic polymer is melt-bonded to the second thermoplastic polymer.

[0032] In a twenty-eighth aspect, embodiments of the present disclosure relate to a fastener driver. The fastener driver includes a cylinder housing. A storage chamber is disposed within the cylinder housing and is configured to hold pressurized gas. A piston sleeve is disposed within the gas storage chamber and a piston is configured to linearly translate within the piston sleeve. A driver blade is attached to the piston such that movement of the piston causes movement of the driver blade to drive a fastener into a workpiece. The piston sleeve includes an outer layer that defines a cylindrical tube and a collar. An interior of the collar is reinforced with a composite component that includes a thermoplastic polymer matrix filled with long fibers.

[0033] A twenty-ninth aspect relates to the fastener driver of the twenty-eighth aspect, wherein the cylindrical tube is lined with an aluminum bore.

[0034] A thirtieth aspect relates to the fastener driver of the twenty-eighth aspect or the twenty-ninth aspect, wherein the thermoplastic polymer matrix of the composite component includes at least one of: polyamide (PA), polycarbonate (PC), polypropylene (PP), polyphthalamide (PPA), poly(butylene terephthalate) (PBT), poly(acrylonitrile:butadiene:styrene) (ABS), or polyketone (POK).

[0035] A thirty-first aspect relates to the fastener driver of the twenty-eighth aspect through the thirtieth aspect, wherein the long fibers include fibers selected from the group consisting of: glass fibers, carbon fibers, aramid fibers, basalt fibers, ultra-high molecular weight polyethylene fibers, and combinations thereof.

[0036] A thirty-second aspect relates to the fastener driver of the twenty-eighth aspect through the thirty-first aspect, wherein the long fibers are randomly oriented.

[0037] A thirty-third aspect relates to the fastener driver of the twenty-eighth aspect through the thirty-second aspect, wherein a majority of the long fibers are oriented within 15° of a common direction.

[0038] A thirty-fourth aspect relates to the fastener driver of the twenty-eighth aspect through the thirty-third aspect, wherein the composite component includes a plurality of layers, and wherein each layer of the plurality of layers includes the thermoplastic polymer matrix filled with long fibers.

[0039] The thirty-fifth aspect relates to the fastener driver of the thirty-fourth aspect, wherein the long fibers in each of the plurality of layers are oriented within 15° of a common direction, and wherein the common direction of a first layer of the plurality of layers is rotated about 45° or about 90° relative to the common direction of an adjacent second layer of the plurality of layers.

[0040] The thirty-sixth aspect relates to the fastener driver of the twenty-eighth aspect through the thirty-fifth aspect, wherein the collar has a radial thickness, and wherein the composite component occupies 80% of the radial thickness.

[0041] The thirty-seventh aspect relates to the fastener driver of the twenty-eighth aspect through the thirty-sixth aspect, wherein the composite component is attached to the outer layer without an adhesive.

[0042] The thirty-eighth aspect relates to the fastener driver of the thirty-seventh aspect, wherein the composite component is fusion bonded to the outer layer.

[0043] The thirty-ninth aspect relates to the fastener driver of the twenty-eighth aspect through the thirty-eighth aspect, wherein the outer layer is formed of the same thermoplastic polymer as the thermoplastic polymer matrix or a second thermoplastic polymer that is compatible with the thermoplastic polymer matrix.

[0044] The fortieth aspect relates to the fastener driver of the thirty-ninth aspect, wherein the outer layer includes short fibers embedded in the same thermoplastic polymer or the second thermoplastic polymer, and wherein a majority of the short fibers have a length of less than 0.5 inches.

[0045] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art who practice the application, and which is further pointed out by the claims, or recognized by practice of the embodiments as described in the written description and / or illustrated in the accompanying drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary.

[0046] The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of the specification. The drawings illustrate one or more embodiment(s) and, together with the description, serve to explain principles and operation of the various embodiments. Additionally, alternative example embodiments relate to other features and combinations of features as can be generally recited in the claims. BRIEF DESCRIPTION OF DRAWINGS

[0047] The application will be more fully understood from the following detailed description taken in connection with the accompanying drawings, in which like reference numerals refer to like elements, and in which:

[0048] Figure 1 a perspective view of a power tool, in particular an impact driver, is depicted according to an embodiment of the present disclosure;

[0049] Figure 2 Depicts a battery pack according to an embodiment of the present disclosure. Figure 1 A cross-sectional view of a power tool;

[0050] Figure 3 Depicts a hybrid composite component of a power tool, particularly an end cap, according to an embodiment of the present disclosure;

[0051] Figure 4 Depicting an embodiment of the present disclosure Figure 3 Exploded view of hybrid composite components;

[0052] Figure 5 Depicting an embodiment of the present disclosure Figure 3 Cross-sectional view of a hybrid composite component;

[0053] Figure 6 depicts a graph of displacement plotted against force applied to an end cap, including a comparative example and two examples according to embodiments of the present disclosure;

[0054] Figure 7 depicts a perspective view of a battery pack that may be reinforced with composite components according to an embodiment of the present disclosure;

[0055] Figure 8 Depicts a corner having composite components reinforced according to an embodiment of the present disclosure. Figure 7 a lower housing member of a battery pack;

[0056] Figure 9 depicts a perspective view of a fastener driver having one or more components reinforced with composite components according to an embodiment of the present disclosure;

[0057] Figure 10 Depicting an embodiment of the present disclosure Figure 9 A partial cross-sectional view of a cylinder housing of a fastener driver;

[0058] Figure 11 Depicting an embodiment of the present disclosure Figure 9 and Figure 10 A cross-sectional view of a cylinder housing and an end effector of a fastener driver;

[0059] Figure 12 depicts a perspective view of a piston sleeve having a collar reinforced with a composite component according to an embodiment of the present disclosure; and

[0060] Figure 13 Tensile stress-strain curves are depicted for an existing piston-sleeve design and a piston-sleeve design with composite part reinforcement according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0061] Various aspects of the present disclosure relate to embodiments of hybrid composite components of power tools configured to provide locally enhanced stiffness and strength of a housing.

[0062] Power tools often experience various loads due to the ruggedness of the structures in which they are used. For example, power tools are often used by an operator on a ladder or atop a structure, and thus, such power tools can be dropped from a significant height. Additionally, power tools can be subjected to significant forces exerted by an operator when working on tough materials. Accordingly, power tools should be mechanically robust enough to withstand reasonable mechanical loads. Additionally, it is desirable to provide lightweight products that an operator can use for extended periods of time. One method of enhancing mechanical robustness is to use stiffer materials, but such material changes often come with an increase in weight. Applicant has recognized that there is a need in the art to balance these potential tradeoffs in power tool design, and has developed a solution that provides enhanced mechanical performance without significantly increasing the weight of the power tool.

[0063] As will be discussed more fully below, embodiments of the disclosed hybrid composite components provide such enhanced mechanical performance, particularly enhanced stiffness and strength, without increasing or substantially increasing the weight of the power tool. According to embodiments, the hybrid composite component includes a housing component and a composite component. The housing component is formed of a thermoplastic polymer, and the composite component includes a thermoplastic polymer matrix filled with long fibers. In one or more embodiments, the housing component provides a desired aesthetic and tactile finish to the exterior of the power tool, while the composite component enhances the stiffness and strength of the housing component. Advantageously, the composite component does not increase or substantially increase the size of the housing, and unlike other rigid materials such as metals, the composite component can be electrically non-conductive and lightweight. These and other aspects and advantages will be described below in connection with exemplary embodiments and drawings, and such discussion is provided as an illustration and not a limitation.

[0064] Figure 1 Embodiments of a power tool 100 are provided, which is depicted as an impact driver; however, the power tool 100 can be any of a variety of power tools, such as a drill, hammer drill, circular saw, reciprocating saw, jigsaw, miter saw, angle grinder, fastener driver, sander, pipe cutter, or cable cutter, among other possible power tools. The power tool 100 includes a housing 102. In one or more embodiments, the housing 102 encloses electronic and electromechanical components for operating the power tool 100.

[0065] In one or more embodiments, the housing 102 includes a first portion 104 and a handle portion 108. In the depicted embodiment, the first portion 104 is a head portion having an end effector 110 of the power tool 100, and in the depicted embodiment, the end effector 110 is configured to hold a drill bit for driving fasteners or for drilling holes. Additionally, in the depicted embodiment, the handle portion 108 has a trigger 112 formed therein to actuate the end effector 110. In the depicted embodiment, the first portion 104 includes a selector 114 that is configured to select the direction in which the end effector 110 is driven (e.g., forward or reverse). In one or more embodiments, including the depicted embodiment, the housing 102 also includes a second portion 106, and the second portion 106 of the power tool 100 is configured to receive a battery pack 116 (e.g., Figure 2 ).

[0066] As will be discussed more fully in conjunction with the depicted embodiment, the first portion 104 includes Figure 2 . For the power tool 100, and in particular the impact driver, the end cap 118 is disposed on one side of the first portion 104, and the end effector 110 is disposed on the opposite side of the first portion 104, such that the end cap 118 and the end effector 110 are linearly aligned. An operator of the power tool 100 can use the end cap 118 to apply pressure to the end effector 110. For example, the operator can press, for example, a knee, elbow, or shoulder against the end cap 118 of the impact driver to apply pressure to the end effector 110 of the impact driver while driving a fastener or a drill bit. If the end cap 118 is not sufficiently rigid and strong, the end cap 118 may bend inward and potentially contact internal components of the housing 102, which may cause the components to operate improperly or deteriorate. Therefore, in one or more embodiments according to the present disclosure, the housing 102 includes one or more localized areas, such as the end cap 118, that are reinforced with a composite material. Other portions particularly suitable for reinforcement (particularly of impact drivers or other power tools in general) include the handle portion 108 and the battery pack 116, which are particularly susceptible to breaking when the power tool is dropped from a height (such as when the operator is on a ladder or roof).

[0067] Figure 3 A hybrid composite component 120 is depicted in the form of a reinforced end cap 118. In such an embodiment, the end cap 118 can be considered a reinforced localized area of ​​the hull 102. Generally, a hybrid composite component 120, such as the end cap 118, includes a hull component 122 that is visible on the exterior of the hull 102 and a composite component 124 that reinforces the hull component 122.

[0068] According to the present disclosure, the composite component 124 is formed from a thermoplastic polymer matrix filled with long fibers. In one or more embodiments, long fibers are considered "long" if a majority of the fibers (i.e., >50%) have a length of at least 0.5 inches. In one or more embodiments, long fibers include fibers in which at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at most 100% of the fibers have a length of at least 0.5 inches. In one or more embodiments, fibers that meet the "long" requirement have a length of at least 0.75 inches, at least 1 inch, at least 1.25 inches, at least 1.5 inches, at least 1.75 inches, at least 2 inches, at least 2.25 inches, at least 2.5 inches, at least 2.5 inches, at least 2.75 inches, or at least 3 inches. Such fibers are distinguished from staple fibers in that most fibers are less than 0.5 inches in length, particularly less than 0.25 inches in length, and typically about 1 / 32 inches or less.

[0069] In one or more embodiments, the long fibers include fibers selected from the group consisting of glass fibers (e.g., E-glass or S-glass), carbon fibers (e.g., 1k tow to 50k tow), aramid fibers, basalt fibers, ultra-high molecular weight polyethylene fibers, and combinations thereof.

[0070] In one or more embodiments, the thermoplastic polymer matrix of the composite component 124 includes at least one of the following: polyamide (PA) (e.g., polyamide 6, polyamide 66, or polyamide 12), polycarbonate (PC), polypropylene (PP), polyphthalamide (PPA), poly(butylene terephthalate) (PBT), poly(acrylonitrile:butadiene:styrene) (ABS), or polyketone (POK). In one or more embodiments, the thermoplastic polymer of the composite component is a blend of two or more of the aforementioned thermoplastic polymers, such as a blend of PC / ABS, PC / PBT, or PA / ABS, among other possible blends.

[0071] In one or more embodiments, composite component 124 includes at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, or up to 70% by weight of long fibers. In one or more specific embodiments, composite component 124 includes 50% to 70% by weight, and more particularly 60% to 65% by weight, of long fibers.

[0072] In one or more embodiments, the composite part 124 includes at least 20 wt%, at least 25 wt%, at least 30 wt%, at least 35 wt%, at least 40 wt%, at least 45 wt%, at least 50 wt%, at least 55 wt%, at least 60 wt%, at least 65 wt%, at least 70 wt%, at least 75 wt%, or at most 80 wt% of the thermoplastic polymer matrix. In one or more particular embodiments, the composite part includes 20 wt% to 80 wt%, in particular 30 wt% to 60 wt%, of the thermoplastic polymer matrix.

[0073] In one or more embodiments, the composite part 124 further includes up to 10 wt% (typically 5 wt% or less) of various process additives and / or modifying additives dispersed in the thermoplastic polymer matrix. Such additives can include heat stabilizers, antioxidants, colorants, lubricating additives, flame retardants, antistatic agents, and thermally / electrically conductive fillers. In one or more embodiments in which the composite part 124 is used in battery pack applications, in particular for lithium-ion battery packs, the composite part 124 includes flame retardant additives, antioxidants, and heat stabilizers.

[0074] In the composite part 124, the long fibers are embedded in the thermoplastic polymer matrix such that the thermoplastic polymer matrix serves as a binder for the long fibers. In one or more embodiments, the long fibers are randomly oriented in the composite part 124. Random orientation of the fibers within the composite part 124 can provide substantially uniform properties regardless of the direction of application of forces. In one or more embodiments, the long fibers are substantially unidirectionally oriented within the composite part 124. In one or more embodiments, at least 50% of the long fibers are oriented within 15° of a common direction, in particular within 10°, and most particularly within 5°. In such embodiments, the unidirectional orientation can provide enhanced strength along the orientation direction (e.g., the composite part 124 has increased resistance to tensile loads applied in the orientation direction as compared to tensile loads applied transverse to the orientation direction). The random orientation and unidirectional orientation of the long fibers can vary depending on the location of the reinforcement and the forces expected to be applied on the shell part being reinforced.

[0075] In one or more embodiments, the shell component 122 is molded around the composite component 124. For example, the composite component 124 can first be prepared from a composite material, formed into a desired preform, and fusion consolidated. Thereafter, the composite component 124 can be placed in a mold, and a molten thermoplastic polymer used to form the shell component 122 can be injected into the mold over or around the composite component 124 to form the shell component 122. The molten thermoplastic material of the shell component 122 can tackify the thermoplastic polymer of the composite component 124 to provide a secure attachment (physical, electrostatic, and / or chemical bonding) between the shell component 122 and the composite component 124. In one or more embodiments, the molten thermoplastic material of the shell component 122 fusion bonds to the composite component 124, fusing to the thermoplastic polymer matrix of the composite component 124. In this manner, no adhesive is required to attach the shell component 122 to the composite component 124. In one or more embodiments, the composite component 124 is pre-heated or heated during deposition of the molten thermoplastic material to enhance the attachment between the composite component 124 and the molten thermoplastic polymer of the shell component 122.

[0076] In one or more other embodiments, the composite component 124 can be constructed from one or more layers of unidirectional fibers bonded in a thermoplastic polymer matrix (i.e., tape) and / or from one or more layers of hybrid structures (i.e., woven or knitted fabrics formed from long fibers and thermoplastic polymer fibers). In one or more embodiments, the composite component 124 is constructed by layering composite tapes with unidirectional fibers having different orientations in each layer. In an example of such an embodiment, a first layer of the composite tape can have a 0° reference direction, and a second layer of the composite tape can be rotated 90° relative to the first layer. Such a composite component formed from layered composite tapes can include, for example, alternating layers of 0° and 90° or, for example, 0°, 45°, 90°, and 135°. In this manner, even though each layer has an axis of enhanced material properties, the combination of layers in the composite component 124 has more uniform properties in multiple load directions, such that the composite component 124 is similar to a randomly oriented composite component. Further, the composite component 124 can be constructed from layers of hybrid structures, such as layers of woven fabrics including fibers woven at +45° / -45°. The layers of hybrid structures can also be oriented, for example, at 0° and 90° or, for example, 0°, 45°, 90°, and 135° alternating. After constructing the layered structure, the layers are fusion consolidated by heating the layers of composite material to fuse the thermoplastic polymer within each layer and to fuse the thermoplastic polymer between the layers.

[0077] In one or more embodiments, each layer of the composite material has a thickness of 0.1 mm to 0.5 mm, particularly 0.1 mm to 0.35 mm. In one or more embodiments, the composite part 124 includes 1 layer of composite material to 30 layers of composite material. In one or more embodiments, the composite part 124 has a thickness of 0.1 mm to 3 mm.

[0078] In one or more embodiments, the shell part 122 is formed from a thermoplastic polymer, particularly the same thermoplastic polymer as used as the thermoplastic polymer matrix of the composite part 124 or a thermoplastic polymer that is compatible with the thermoplastic polymer used in the composite part 124. In one or more embodiments, the thermoplastic polymer of the shell part 122 is filled with short fibers that are shorter than the long fibers of the composite part 124. Further, as used herein, fibers are considered to be “short” if a majority of the fibers (i.e., > 50% of the fibers) in the polymer of the shell part 122 have a length of less than 0.5 inches, particularly less than 0.25 inches, and most particularly about 1 / 32 inch or less. In one or more embodiments, the short fibers include fibers in which at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or up to 100% of the fibers have a length of less than 0.5 inches. Such fibers are distinct from the long fibers as described above. In one or more embodiments, the shell part 122 includes up to 20 wt%, up to 30 wt%, up to 40 wt%, up to 50 wt%, up to 60 wt%, or up to 70 wt% of short fibers. In one or more embodiments, the shell part 122 includes at least 1 wt%, at least 5 wt%, or at least 10 wt% of short fibers. In one or more embodiments, the short fibers include fibers selected from the group consisting of glass fibers, carbon fibers, aramid fibers, basalt fibers, ultra-high molecular weight polyethylene fibers, and combinations thereof. The shell part 122 can also include various other additives, such as those listed above.

[0079] Whether the thermoplastic polymer of the shell part 122 includes short fibers can be based on the particular combination of materials used for the shell part 122 and the composite part 124. For example, the shell part 122 can be composed of polycarbonate without short fibers, and the composite part 124 can be composed of a polycarbonate matrix with long carbon fibers. In another example, the shell part 122 can be composed of polyamide 66 filled with short fibers, and the composite part 124 can be composed of polyamide 66 filled with long carbon fibers or long glass fibers. These are merely example embodiments, and other combinations and possibilities can be contemplated.

[0080] In one or more embodiments, the composite part 124 is directly attached to the shell part 122 by physical, electrostatic, and / or chemical interactions. In one or more embodiments, the composite part 124 is formed from the same base polymer as the shell part 122. For example, if the shell part 122 is formed primarily from polyamide 66, the thermoplastic polymer of the composite part 124 can also be selected to be polyamide 66. In this way, particularly without the need for adhesives, the polymer of the composite part 124 is compatible with and will attach to the host polymer of the shell part 122. In embodiments in which the shell part 122 is applied as a molten material, the deposition of the molten material will facilitate the fusion bonding between the composite part 124 and the shell part 122 as described above.

[0081] Figure 4 An exploded view of the hybrid composite part 120 is depicted. The shell part 122 includes an inner surface 126 and an outer surface 128 that define a shell wall 130. For the end cap 118, the shell wall 130 is substantially planar, but for other hybrid composite parts 120 such as in the handle portion 108, the shell wall 130 can include one or more curved portions (e.g., including a profile designed for engagement with an operator's hand). In one or more embodiments, the composite part 124 is a conformal layer over the planar or curved inner surface 126 of the shell wall 130.

[0082] Nonetheless, the shell part 122 can include one or more protruding elements. For example, Figure 4 The end cap 118 shown in FIG. 1 1 1 includes a central alignment pin 132 extending from the inner surface 126 as well as a collar 134 defining a through hole for a fastener to attach the end cap 118 to the remainder of the shell 102. Advantageously, by shaping the shell part 122 of the end cap 118 formed from a thermoplastic polymer (as appropriate, which can or can not include short fibers), complex geometries including curved surfaces and protruding elements can be easily molded by techniques such as injection molding or compression molding. Further, the composite part 124 can be preformed in a planar structure or on a curved mold and then fusion consolidated to provide the desired shape. Thereafter, apertures or other cutout features can be formed in the composite part 124 to allow the complex geometry of the shell part 122 to be molded through or around the composite part 124 while also fusing the shell part 122 and the composite part 124 by fusion bonding. For example, the composite part 124 can be formed from the layers of the composite tape as a large sheet, and the sheet can be cut or punched to yield composite part 124 inserts that are joined to the shell part 122.

[0083] Figure 5A cross-sectional view of a hybrid composite part 120 is depicted. Figure 5 The hybrid composite component 120 in the depiction is the end cap 118, but the following discussion also applies to other hybrid composite components 120, such as the handle portion 108 and the battery pack 116. Figure 5 As can be seen in FIG, the shell wall 130 and the composite component 124 define a total thickness T. In one or more embodiments, the composite component 124 comprises at most 80%, at most 70%, at most 60%, at most 50%, at most 40%, at most 30%, at most 20%, or at most 10% of the total thickness T. In one or more embodiments, the composite component 124 comprises at least 1%, at least 2%, at least 5%, or at least 10% of the total thickness T. In one or more specific embodiments, the composite component 124 comprises from 1% to 80%, and particularly from 50% to 80%, of the total thickness T.

[0084] Advantageously, composite component 124 can be used to locally reinforce shell 102 without increasing the thickness of the shell in that localized area. Using end cap 118 as an example, the total thickness T of end cap 118 can be the same as the wall thickness of a conventional, non-reinforced, all-plastic end cap. In this way, end cap 118 is reinforced to increase rigidity without requiring significant redesign of shell 102. In one or more embodiments, hybrid composite component 120 has twice the rigidity of a conventional, non-reinforced shell component. Furthermore, composite component 124 provides an additional level of protection for shell 102 in the event that shell component 122 is cracked or punctured. That is, a crack or puncture through plastic shell component 122 will not automatically propagate through composite component 124. Therefore, damage to shell component 122 will not necessarily lead to failure of shell 102.

[0085] Figure 6 A graph of displacement (mm) versus force (lbf) required to produce the displacement is provided. The graph considers three samples. The first sample 201 is an example of a composite part 124 according to the present disclosure, which is composed of polyamide 66 (available from Avient Corporation, Avon Lake, Ohio) with 60% by weight long glass fiber. The first sample 201 has a thickness of 0.90 mm and is composed of 8 unidirectional layers (alternating 0° / 90°). As shown in Figure 6 As can be seen in FIG, a force of more than 550 lbf is required for a deflection of about 3 mm for the first sample 201. The second sample 202 is a comparative example composed of polyamide 6 (available from Kingfa Sci&Tech Co Ltd, Guangzhou, China) with 30% by weight of short glass fiber. Figure 6As can be seen, a 3 mm deflection for the second sample 202 required only about 325 lbf of force. Thus, the use of higher amounts of long fibers results in a significant increase in the force required to produce a given deflection. The third sample 203 is another example of a composite part 124 according to the present disclosure, which is composed of polyamide 6 (available from Celanese Corporation, Irving, Texas (USA)) with 60 wt% long carbon fibers. The third sample 203 has a thickness of 0.90 mm and is composed of 8 unidirectional layers (alternating 0° / 90°). As in Figure 6 As can be seen, a 3 mm deflection for the third sample 203 required over 750 lbf of force.

[0086] Further, taking the first sample 201 and the second sample 202, each sample was able to withstand a peak force of about 700 lbf. However, when such a force was applied, the first sample 201 deflected only about 3.6 mm, while the second sample 202 deflected about 5.7 mm. The third sample 203 exhibited an even higher peak force of over 1300 lbf, and at this force, deflected only about 4.3 mm. Thus, in terms of resistance to deflection under load, the samples according to the present disclosure provide enhanced stiffness as compared to conventional short fiber composites.

[0087] While portions of the foregoing description discuss embodiments of hybrid composite parts 120 in the form of end caps 118 of impact drivers, other portions of the power tool 100 can also be locally reinforced with composite parts 124. Referring to Figure 2 the foregoing discussion specifically mentions the use of composite parts 124 to reinforce the handle portion 108 and to reinforce the battery pack 116 locally. For example, the handle portion 108 can be reinforced at the first location 136 where the handle portion 108 transitions to the second portion 106. Additionally or alternatively, the handle portion 108 can be reinforced at the second location 138 where an operator grasps the handle portion 108. Additionally or alternatively, the handle portion 108 can be reinforced at the location 140 where the handle portion 108 transitions to the first portion 104. Such reinforcements can be provided to increase the force required to crush the handle portion 108 when the power tool 100 is dropped.

[0088] As another example, the battery pack 116 can be reinforced along one or more of the top, bottom, or side walls 142. In one or more embodiments, the battery pack 116 is formed from an upper housing and a lower housing that fit and fasten together, and the top, bottom, and / or side walls 142 of each housing are reinforced with composite components 124. Additionally or alternatively, the battery pack 116 can be reinforced at one or more of the corners 144. Such reinforcement of the battery pack 116 can help prevent damage to the battery cells contained within the battery pack 116 when the power tool 100 is dropped.

[0089] Figure 7 An example embodiment of a battery pack 116 is depicted. In one or more embodiments, the battery pack 116 includes a lower housing component 146 and an upper housing component 148. As can be seen in Figure 7 the battery pack 116 can include features such as a power tool attachment / charging station attachment mount 150. The mount 150 includes electrical contacts 152 configured to allow charging / discharging of battery cells (not shown) contained within the battery pack 116. The mount 150 can also include a locking element 154 and a release mechanism 156. The locking element 154 can engage with a charging station or power tool when the mount 150 is fully inserted into the charging station or power tool to prevent the battery pack 116 from freely sliding. Upon actuation of the release mechanism 156, the locking element 154 will disengage from the charging station or power tool. Additionally, the battery pack 116 can include a charge indicator 158 such as a set of LED lights 160 that indicate the charge level of the battery cells in the battery pack 116. Furthermore, the battery pack 116 can include control electronics designed to prevent overcharging and overheating of the battery cells.

[0090] Figure 8 A lower housing component 146 is depicted. As can be seen, the lower housing component 146 includes a plurality of side walls 142. Disposed between the side walls 142 are corners 144, which in the embodiment shown in Figure 8 are angled or faceted corners. In one or more embodiments, one or more of the corners 144 are hybrid composite components 120, where the housing component 120 is reinforced with composite components 124 as described above. Figure 8 A top corner 144 of the lower housing component 146 reinforced with composite components 124 is depicted, although in one or more other embodiments, the entire corner 144 or a bottom portion of the corner 144 can be reinforced. Additionally, all or a portion of the bottom wall 162 can additionally or alternatively be reinforced with composite components 124.

[0091] Figures 9 to 13Another embodiment involving a power tool 300, in particular a fastener driver, includes hybrid composite components. As in the embodiment depicted in Figure 9 The fastener driver 300 is a hand-held device configured to drive fasteners, such as nails, tacks, or pins, and other possible fasteners, supplied from a cartridge 302 into a workpiece. As with the embodiment of the power tool 100 described above, the fastener driver 300 includes a first portion 304 connected to a handle portion 308. The handle portion 308 is in turn connected to a second portion 306. In one or more embodiments, the head portion 306 includes an end effector 310 configured to drive fasteners, in particular using a gas spring mechanism. The handle portion 308 includes a trigger 312 formed therein to actuate the end effector 310. The first portion 304, the handle portion 308, and the second portion 306 make up a housing 314 of the fastener driver 300. Further, in the illustrated embodiment, the second portion 306 is configured to receive a battery pack 316. As described above, the housing 314 of the fastener driver 300 and / or the battery pack 316 can include one or more localized areas reinforced with composite components. Further, for the fastener driver 300, internal components of the gas spring mechanism are also suitable for reinforcement with composite components, and the simplified discussion of the operation of the fastener driver 300 below is used to identify particular components suitable for reinforcement.

[0092] As shown in Figure 9 The first portion 304 includes a gas cylinder housing 320. Figure 10 A partial cross-sectional view of the first portion 304 including the gas cylinder housing 320 is provided. As can be seen in Figure 10 The gas cylinder housing 320 surrounds a reservoir cylinder 322 that contains pressurized gas. The reservoir cylinder 322 is mounted in a gas cylinder support 324. Mechanical components of the end effector 310 are linearly arranged in alignment with the reservoir cylinder 322, such that the gas cylinder support is disposed between the reservoir cylinder 322 and the end effector 310. The end effector 310 includes a latch assembly 326 that controls the positioning of a driver blade 330 and a lift assembly 328, as shown in the cross-sectional view of Figure 11

[0093] As can be seen in Figure 11 The driver blade 330 is connected to a piston 332 contained within a piston sleeve 334, which is contained within the reservoir cylinder 322. In Figure 11 ​In the embodiment shown in FIG. 3, the piston 332, and thus the driver blade 330, is in a ready position at a first end 336 of the piston sleeve 334 distal from the cylinder support 324. As mentioned, the reservoir cylinder 322 is filled with pressurized gas, and when the latch assembly 326 is released, the pressurized gas in the reservoir cylinder 322 drives the piston 332 toward a second end 338 of the piston sleeve 334 proximal to the cylinder support 324. A bumper 340 and a conical washer 342 are disposed within the cylinder support 324. The bumper 340 absorbs the impact energy of the piston 332, and the conical washer 342 evenly distributes the impact force of the piston 332 across the bumper 340. After driving the piston 332, the lift assembly 328 engages the driver blade 330 to return the piston 332 to the ready position at the first end 336 of the piston sleeve 334. In particular, the lift assembly 328 includes a cam 344 having a plurality of pins 346 configured to engage teeth 348 of the driver blade 330. The cam 344 is attached to a shaft driven by a motor, such that after actuating the trigger 312 to release the latch assembly 326, the lift assembly 328 returns the driver blade 330 and the piston 332 to the ready position. A more detailed description of the operation of the fastener driver 300 can be found in Applicant’s U.S. Patent No. 10,173,310, entitled “Gas Spring-Powered Fastener Driver,” published January 8, 2019, the entirety of which is incorporated by reference herein.

[0094] Having described the operation of the fastener driver 300, a component that is particularly well suited for reinforcement with a composite component is the piston sleeve 334 as shown in Figure 12 FIG. 3. In one or more embodiments, the piston sleeve 334 includes a cylindrical tube 350 having a collar 352. In one or more embodiments, the collar 352 includes one or more grooves 354 configured to carry a washer 356 (as shown in Figure 11 FIG. 3). The collar 352 and the washer 356 engage an inner wall 358 of the reservoir cylinder 322 to provide a fluid-tight seal.

[0095] Returning to Figure 12 FIG. 3, the piston sleeve 334 includes an outer layer 360 composed of a thermoplastic polymer. In one or more embodiments, the thermoplastic polymer can include short fibers. In one or more embodiments, the thermoplastic polymer and short fibers of the outer layer 360 correspond to the thermoplastic polymer and short fibers described above with respect to the housing component 122.

[0096] In the barrel tube 350, the outer layer 360 surrounds an aluminum bore 362, which provides a sliding surface for the piston 332. The aluminum bore 362 extends from the first end 336 of the piston sleeve 334 to the collar 352 (but does not extend into the collar 352).

[0097] Within the collar 352, the piston sleeve 334 is lined with a composite part 364. The composite part 364 includes a thermoplastic polymer matrix and long fibers as described above with respect to the composite part 124, including in the selection of the thermoplastic polymer of the matrix: the type, length, and orientation of the long fibers; a layered structure or a non-layered structure; and the relative thickness compared to the overall thickness. Further, as described above, the composite part 364 is joined to the outer layer 360 without an adhesive, particularly by melt bonding the thermoplastic polymer matrix of the composite part 364 to the thermoplastic polymer of the outer layer 360. Thus, the piston sleeve 334 includes a hybrid composite part 366 in the form of the composite part 364 as a partial reinforcement of the collar 352 of the outer shell 360.

[0098] In certain existing piston sleeve designs, the collar is not partially reinforced, and after the outer layer is injection molded around the aluminum bore, the collar can develop cracks along the injection molded weld line extending from the second end to the barrel tube. Figure 13 Figure 13 A graph of tensile strength is provided for comparison of an existing piston sleeve design compared to the piston sleeve 334 having the hybrid composite part 364 according to the present disclosure. The samples used to generate the graph were conditioned to 1.7% moisture content and subjected to tensile loading. The stress-strain curve 401 for the existing design exhibits a tensile strength of less than 9 ksi at about 2% strain. In contrast, the stress-strain curve 402 for the piston sleeve 334 according to the present disclosure exhibits a tensile strength of more than 16 ksi at greater than 8% strain. Thus, the partial reinforcement of the collar 352 with the composite part 364 substantially strengthens the piston sleeve 334 of the fastener driver 300 to prevent cracking along the injection molded weld line under typical operating conditions.

[0099] It should be understood that the drawings detail exemplary implementations and that the application should not be limited to the details or methodology set forth in the description or depicted in the drawings. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

[0100] In view of this description, other modifications and alternative embodiments of various aspects of the present disclosure will be obvious to those skilled in the art. Therefore, this description is to be interpreted as illustrative only. The configurations and arrangements shown in the various exemplary embodiments are illustrative only. Although only a few embodiments are described in detail in this disclosure, many modifications (for example, changes in the size, dimensions, structure, shape and proportion of various elements, the value of parameters, installation arrangements, the use of materials, colors, orientations, etc.) are possible without departing substantially from the novel teachings and advantages of the subject matter described herein. Some elements shown as being integrally formed can be constructed from multiple parts or elements, the position of the elements can be reversed or otherwise changed, and the nature or number or position of the discrete elements can be changed or varied. The order or sequence of any process, logical algorithm or method steps can be changed or reordered according to alternative embodiments. Without departing from the scope of this disclosure, other replacements, modifications, changes and omissions can also be made to the design, operating conditions and arrangements of the various exemplary embodiments.

[0101] Unless otherwise expressly stated, it is in no way intended that any method described herein be construed as requiring that its steps be performed in a specific order. Therefore, in the absence of a method claim actually reciting an order to be followed by its steps or in the absence of other specific indications in the claims or description that the steps should be limited to a specific order, it is in no way intended to infer any specific order. Furthermore, as used herein, the article "a" is intended to include one or more components or elements and is not intended to be construed as meaning only one.

Claims

1. An electric tool comprising: at least one hybrid composite component comprising a shell component and a composite component; wherein the composite component is made of a first thermoplastic polymer matrix filled with long fibers; and A majority of the long fibers have a length of at least 0.5 inches.

2. The electric tool according to claim 1, wherein The first thermoplastic polymer matrix of the composite part includes at least one of the following: polyamide (PA), polycarbonate (PC), polypropylene (PP), polyphthalamide (PPA), poly(butylene terephthalate) (PBT), poly(acrylonitrile:butadiene:styrene) (ABS), or polyketone (POK).

3. The electric tool according to claim 1 or claim 2, wherein: The long fibers include fibers selected from the group consisting of glass fibers, carbon fibers, aramid fibers, basalt fibers, ultra-high molecular weight polyethylene fibers, and combinations thereof.

4. The electric power tool according to any one of claims 1 to 3, wherein The long fibers are randomly oriented.

5. The electric power tool according to any one of claims 1 to 4, wherein The majority of the long fibers are oriented within 15° of a common direction.

6. The electric power tool according to any one of claims 1 to 5, wherein: The composite component comprises a plurality of layers, and wherein each layer of the plurality of layers comprises the first thermoplastic polymer matrix filled with the long fibers.

7. The electric power tool according to claim 6, wherein: The long fibers in each of the plurality of layers are oriented within 15° of a common direction, and wherein the common direction of a first layer of the plurality of layers is rotated by about 45° or about 90° relative to the common direction of an adjacent second layer of the plurality of layers.

8. The electric power tool according to any one of claims 1 to 7, wherein: The hybrid composite component has a thickness, and wherein the composite component comprises 80% of the thickness.

9. The electric power tool according to any one of claims 1 to 8, wherein: The composite component is attached to the shell component without adhesive.

10. The electric power tool according to any one of claims 1 to 9, wherein The housing component is formed from the same thermoplastic polymer as the first thermoplastic polymer matrix or a second thermoplastic polymer that is compatible with the first thermoplastic polymer matrix.

11. The electric power tool according to claim 10, wherein: The shell component includes staple fibers embedded in the same thermoplastic polymer or the second thermoplastic polymer, and wherein a majority of the staple fibers have a length of less than 0.5 inches.

12. The electric power tool according to any one of claims 1 to 11, wherein At least one of the hybrid composite components comprises an end cap of an impact driver.

13. The electric power tool according to any one of claims 1 to 12, wherein: At least one of the hybrid composite components includes a handle portion.

14. The electric power tool according to any one of claims 1 to 13, wherein: At least one of the hybrid composite components comprises a battery pack.

15. The electric power tool according to any one of claims 1 to 11, wherein The power tool is a fastener driver including a gas spring mechanism, wherein the gas spring mechanism includes a piston-cylinder, and wherein at least one of the hybrid composite components includes the piston-cylinder.

16. An electric tool comprising: a housing comprising a first thermoplastic polymer; and a composite component that reinforces a localized area of ​​the shell; wherein the composite component comprises a matrix filled with long fibers, the matrix comprising a second thermoplastic polymer; and wherein the first thermoplastic polymer of the housing is melt bonded to the second thermoplastic polymer of the composite component.

17. The electric power tool according to claim 16, wherein: Most of the long fibers have a length of at least 0.5 inches.

18. The electric tool according to claim 16 or claim 17, wherein: The composite component includes 50% to 70% by weight of the long fibers.

19. The electric power tool according to any one of claims 16 to 18, wherein: The composite component comprises a first thickness in the range of 0.1 mm to 3 mm.

20. The electric power tool according to claim 19, wherein The localized area of ​​the housing has a second thickness, wherein the first thickness and the second thickness together equal a total thickness, and wherein the first thickness is up to 80% of the total thickness.

21. An impact driver comprising: a housing comprising a head portion and a handle portion; an end effector disposed on a first side of the head portion, the end effector configured to hold a drill bit configured for drilling a hole or for driving a fastener; an end cap disposed on a second side of the head portion opposite the end effector; a trigger disposed in the handle portion, the trigger configured to actuate the end effector; wherein the end cap is a hybrid composite component comprising a shell component and a composite component; and Therein, the composite component comprises long fibers disposed within a matrix of a first thermoplastic polymer.

22. The impact driver of claim 21, wherein The shell component includes a second thermoplastic polymer, and wherein the second thermoplastic polymer of the shell component is melt bonded to the first thermoplastic polymer of the composite component.

23. An impact driver according to claim 21 or claim 22, wherein The end cap is configured to deflect by no more than 3 mm when a force of 550 lbf is applied perpendicular to the housing member on the housing.

24. A battery pack comprising: a first housing component; as well as a second housing component configured to mate with the first housing component; as well as a plurality of battery cells disposed within the first housing member and the second housing member when the first housing member and the second housing member are engaged; wherein the second housing component comprises a plurality of side walls and a plurality of corners, wherein each side wall of the plurality of side walls is connected to an adjacent side wall at a corner of the plurality of corners; and Therein, at least one side wall or corner is reinforced with a composite component comprising a thermoplastic polymer matrix filled with long fibers.

25. The battery pack according to claim 24, wherein: Most of the long fibers have a length of at least 0.5 inches.

26. The battery pack according to claim 24 or claim 25, wherein: The composite component includes 50% to 70% by weight of the long fibers.

27. The battery pack according to any one of claims 24 to 26, wherein: The thermoplastic polymer matrix includes a first thermoplastic polymer, wherein the second housing component includes a second thermoplastic polymer, and wherein the first thermoplastic polymer is melt bonded to the second thermoplastic polymer.

28. A fastener driver comprising: Cylinder housing; a storage chamber disposed within the cylinder housing, the storage chamber configured to hold pressurized gas; a piston sleeve, the piston sleeve being disposed in the storage chamber; a piston configured to translate linearly within the piston sleeve; a driver blade attached to the piston such that movement of the piston causes movement of the driver blade to drive a fastener into a workpiece; wherein the piston sleeve comprises an outer layer defining a cylindrical tube and a collar; and The interior of the collar is reinforced with a composite component comprising a thermoplastic polymer matrix filled with long fibers.

29. The fastener driver of claim 28, wherein The cylindrical tube is lined with aluminum holes.

30. The fastener driver of claim 28 or claim 29, wherein The thermoplastic polymer matrix of the composite part includes at least one of the following: polyamide (PA), polycarbonate (PC), polypropylene (PP), polyphthalamide (PPA), poly(butylene terephthalate) (PBT), poly(acrylonitrile:butadiene:styrene) (ABS), or polyketone (POK).

31. The fastener driver of any one of claims 28 to 30, wherein The long fibers include fibers selected from the group consisting of glass fibers, carbon fibers, aramid fibers, basalt fibers, ultra-high molecular weight polyethylene fibers, and combinations thereof.

32. The fastener driver of any one of claims 28 to 31 , wherein: The long fibers are randomly oriented.

33. The fastener driver of any one of claims 28 to 32, wherein: The majority of the long fibers are oriented within 15° of a common direction.

34. The fastener driver of any one of claims 28 to 33, wherein The composite component comprises a plurality of layers, and wherein each layer of the plurality of layers comprises the thermoplastic polymer matrix filled with the long fibers.

35. The fastener driver of claim 34, wherein: The long fibers in each of the plurality of layers are oriented within 15° of a common direction, and wherein the common direction of a first layer of the plurality of layers is rotated by about 45° or about 90° relative to the common direction of an adjacent second layer of the plurality of layers.

36. The fastener driver of any one of claims 28 to 35, wherein The collar has a radial thickness, and wherein the composite component comprises 80% of the radial thickness.

37. The fastener driver of any one of claims 28 to 36, wherein The composite component is attached to the outer layer without adhesive.

38. The fastener driver of claim 37, wherein: The composite component is fusion bonded to the outer layer.

39. The fastener driver of any one of claims 28 to 38, wherein The outer layer is formed from the same thermoplastic polymer as the thermoplastic polymer matrix or a second thermoplastic polymer that is compatible with the thermoplastic polymer matrix.

40. The fastener driver of claim 39, wherein: The outer layer comprises staple fibers embedded in the same thermoplastic polymer or the second thermoplastic polymer, and wherein a majority of the staple fibers have a length of less than 0.5 inches.

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